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MANUAL TRANSMISSION

C TRANSMISSION/TRANSAXLE

SECTION
MANUAL TRANSMISSION
MT B

E
CONTENTS
PRECAUTIONS ......................................................... 2 . SHIFT CONTROL .................................................... 13 . F
Precautions for Battery Service ............................... 2 . Removal and Installation ....................................... 13 .
Caution .................................................................... 2
. REMOVAL .......................................................... 13
.
PREPARATION .......................................................... 3 . INSTALLATION .................................................. 15 . G
Special Service Tools .............................................. 3 . INSPECTION AFTER INSTALLATION ............... 17 .
Commercial Service Tools ....................................... 6 . AIR BREATHER HOSE ........................................... 18 .
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ....................................... 18 .
H
TROUBLESHOOTING ............................................... 7 . TRANSMISSION ASSEMBLY ................................. 19 .
NVH Troubleshooting Chart .................................... 7 . Removal and Installation from Vehicle .................. 19 .
MANUAL TRANSMISSION .................................. 7 . REMOVAL .......................................................... 19
.
DESCRIPTION ........................................................... 8. INSTALLATION .................................................. 21 . I
Cross-Sectional View .............................................. 8 . Component Parts Drawing .................................... 22 .
DOUBLE-CONE SYNCHRONIZER ..................... 8 . CASE COMPONENTS ....................................... 22 .
TRIPLE-CONE SYNCHRONIZER ....................... 9 . GEAR COMPONENTS ...................................... 23 . J
M/T OIL .................................................................... 10
. SHIFT CONTROL COMPONENTS .................... 25 .
Replacement ......................................................... 10. Disassembly and Assembly ................................... 27 .
DRAINING .......................................................... 10. DISASSEMBLY .................................................. 27 .
K
FILLING .............................................................. 10
. INSPECTION AFTER DISASSEMBLY ............... 37 .
Checking ............................................................... 10
. ASSEMBLY ........................................................ 41.
OIL LEAKAGE AND OIL LEVEL ........................ 10 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 58 .
REAR OIL SEAL ......................................................11 . General Specifications ........................................... 58 . L
Removal and Installation ........................................11 . End Play ................................................................ 58
.
REMOVAL ...........................................................11 . Snap Rings ............................................................ 59
.
INSTALLATION ...................................................11 . Baulk Ring Clearance ............................................ 60 . M
POSITION SWITCH ................................................. 12 .
Checking ............................................................... 12
.
COMPONENT LOCATION ................................. 12 .
BACK-UP LAMP SWITCH ................................. 12 .
NEUTRAL POSITION SWITCH ......................... 12 .

Revision: 2004 December MT-1 2004.5 350Z
PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Battery Service ACS004NG

Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Caution ACS004NF

q Do not reuse transmission oil, once it has been drained.
q Check oil level or replace oil with vehicle on level ground.
q During removal or installation, keep inside of transmission clear of dust or dirt.
q Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.
q In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
q Be careful not to damage sliding surfaces and mating surfaces.

Revision: 2004 December MT-2 2004.5 350Z
PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ACS004NH

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
B
(Kent-Moore No.) Description
Tool name

ST30911000 q Main shaft bearing installation MT
( -- ) q 5th-6th synchronizer assembly installation
a: 98 mm (3.86 in) dia.
b: 40 mm (1.57 in) dia. q Reverse main gear bushing installation
D
Inserter q 3rd gear bushing installation
q 3rd-4th synchronizer assembly installation

ZZA0920D
E
ST30022000 q 3rd main gear installation
( -- ) q 4th main gear installation
a: 110 mm (4.33 in) dia.
b: 46 mm (1.81 in) dia. F
Inserter

G
ZZA0920D

ST27861000 q 1st-2nd synchronizer assembly installation
( -- ) q 1st gear bushing installation
a: 62 mm (2.44 in) dia. H
b: 52 mm (2.05 in) dia.
Support ring
I
ZZA0832D

ST33400001 Rear oil seal installation
(J-26082) J
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
Drift
K

ZZA0814D

KV381054S0 Remove rear oil seal L
( -- )
Oil seal puller

ZZA0601D

ST30032000 Counter rear bearing inner race installation
(J-26010-01)
a: 80 mm (3.15 in) dia.
b: 31 mm (1.22 in) dia.
Inserter

ZZA0920D

Revision: 2004 December MT-3 2004.5 350Z
PREPARATION

Tool number
(Kent-Moore No.) Description
Tool name

KV32102700 Main drive gear bearing installation
( -- )
a: 48 mm (1.89 in) dia.
b: 41 mm (1.61 in) dia.
Drift

ZZA0534D

ST23860000 Reverse counter gear installation
( -- )
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
Drift

ZZA0534D

ST01530000 Reverse synchronizer assembly installation
( -- )
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
Drift

ZZA0534D

ST35291000 Striking rod oil seal installation
( -- )
a: 40 mm (1.57 in) dia.
b: 29.5 mm (1.161 in) dia.
c: 22.5 mm (0.886 in) dia.
Drift

SCIA1575E

KV40100630 4th counter gear thrust washer installation
(J-26092)
a: 67 mm (2.64 in) dia.
b: 38 mm (1.50 in) dia.
Inserter

ZZA0920D

KV38102100 Front cover oil seal installation
(J-25803-01)
a: 44 mm (2.36 in) dia.
b: 28 mm (1.10 in) dia.
Drift

NT084

KV32103300 Reverse synchronizer assembly installation
(J-46529)
Press plate
a: 73 mm (2.87 in)

PCIB0165J

Revision: 2004 December MT-4 2004.5 350Z
PREPARATION

Tool number
(Kent-Moore No.) Description A
Tool name

ST30031000 Inner baulk ring support
(J-22912-01) B
Puller

ZZC0499D

ST22490000 Hold a adapter plate D
( -- )
Adapter setting plate

ZZC0465D
F

Revision: 2004 December MT-5 2004.5 350Z
PREPARATION

Commercial Service Tools ACS004NI

Tool name Description

Puller Each bearing, gear and bushing removal

ZZB0823D

Pin punch Each retaining pin removal and installation
Tip diameter: 6.0 mm (0.24 in) dia.

ZZA0815D

Power tool Loosening bolts and nuts

PBIC0190E

Puller Reverse synchronizer assembly removal
Reverse counter gear removal
Reverse main gear removal

NT077

Revision: 2004 December MT-6 2004.5 350Z
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
A
NVH Troubleshooting Chart ACS004NJ

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts. B
MANUAL TRANSMISSION

MT-10

MT-22

MT-13

MT-25

MT-25
Reference page MT

CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
D

SUSPECTED PARTS G
(Possible cause)

SHIFT CONTROL LINKAGE (Worn)

BAULK RING (Worn or damaged)
BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)

INSERT SPRING (Damaged)
H

GEAR (Worn or damaged)
OIL (Oil level is high.)

GASKET (Damaged)

SHIFT FORK (Worn)
OIL (Oil level is low.)

I
OIL (Wrong oil.)

Noise 1 2 3 3
K
Oil leakage 3 1 2 2
Symptoms
Hard to shift or will not shift 1 1 2 2 2
Jumps out of gear 1 1 2 2 L

Revision: 2004 December MT-7 2004.5 350Z
DESCRIPTION

DESCRIPTION PFP:00000

Cross-Sectional View ACS004NK

PCIB0672E

1. Front cover 2. Main drive gear 3. 5th-6th synchronizer hub
4. 5th-6th coupling sleeve 5. Transmission case 6. 6th main gear
7. 2nd main gear 8. 1st-2nd synchronizer hub 9. 1st-2nd coupling sleeve
10. 1st main gear 11. 3rd main gear 12. 4th main gear
13. Reverse main gear 14. Reverse coupling sleeve 15. Reverse synchronizer hub
16. Striking rod 17. Counter shaft 18. Filler plug
19. 6th counter gear 20. 2nd counter gear 21. 1st counter gear
22. 3rd counter gear 23. 3rd-4th synchronizer hub 24. 3rd-4th coupling sleeve
25. Drain plug 26. 4th counter gear 27. Reverse idler gear
28. Reverse idler shaft 29. Reverse counter gear 30. Main shaft
31. Rear extension

DOUBLE-CONE SYNCHRONIZER
The 1st and 3rd, 4th gears is equipped with a double-cone synchronizer to reduce the operating force of the
shift lever as shown.

Revision: 2004 December MT-8 2004.5 350Z
DESCRIPTION

TRIPLE-CONE SYNCHRONIZER
The 2nd gear is equipped with a triple-cone synchronizer to reduce the operating force of the shift lever as A
shown.

PCIB0594E

Revision: 2004 December MT-9 2004.5 350Z
M/T OIL

M/T OIL PFP:KLD20

Replacement ACS004NL

DRAINING
1. Start the engine and warm up the transmission unit sufficiently.
2. After stopping engine, remove filler plug and drain plug and then drain fluid.
3. After replace a new gasket on drain plug, screw drain plug into transmission body and tighten to the spec-
ified torque. Refer to MT-22, "CASE COMPONENTS" .
CAUTION:
Gaskets are not reusable. Never reuse them.
FILLING
1. Remove filler plug. Fill new oil into the transmission to the level of the filler plug mounting hole.
Oil grade: API GL-4
Viscosity: Refer to MA-12, "Fluids and Lubricants" .
Oil capacity: Approx. 2.9 (3-1/8 US qt, 2-1/2 lmp qt)
2. After filling, check fluid level, replace a new gasket on filler plug, screw filler plug into transmission body,
and tighten to the specified torque. Refer to MT-22, "CASE COMPONENTS" .
CAUTION:
Gaskets are not reusable. Never reuse them.
Checking ACS004NM

OIL LEAKAGE AND OIL LEVEL
q Check if oil is leaking from transmission or around it.
q Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Never start engine while checking oil level.
q When screwing in filler plug with a new gasket, first screw into
the transmission by hand, then tighten to the specified torque.
Refer to MT-22, "CASE COMPONENTS" .
CAUTION:
Gaskets are not reusable. Never reuse them.
PCIB0268E

Revision: 2004 December MT-10 2004.5 350Z
REAR OIL SEAL

REAR OIL SEAL PFP:33140
A
Removal and Installation ACS004NN

REMOVAL
1. Remove propeller shaft. Refer to PR-7, "REMOVAL" .
B
CAUTION:
Do not impact or damage propeller shaft tube.
2. Using oil seal puller, remove rear oil seal. MT
Tool number : KV381054S0 ( -- )

PCIB0194E
E
INSTALLATION
1. Apply multi-purpose grease to rear oil seal lip. Using a drift,
drive in rear oil seal until the edge is approximately 1.2 - 2.2 mm F
(0.047 - 0.087 in) above the boss edge.
Tool number : ST33400001 (J-26082)
CAUTION: G
q Rear oil seals are not reusable. Never reuse them.

q When installing, do not incline the rear oil seal.
H

L
PCIB0595E

2. Install propeller shaft. Refer to PR-8, "INSTALLATION" .
CAUTION: M
q Do not impact or damage propeller shaft tube.

q If lubricant leak has occurred, after finishing work, check oil level. Refer to MT-10, "Checking" .

Revision: 2004 December MT-11 2004.5 350Z
POSITION SWITCH

POSITION SWITCH PFP:32005

Checking ACS004NO

COMPONENT LOCATION

PCIB0622E

BACK-UP LAMP SWITCH
q Check continuity.
Gear position Continuity
Reverse Yes
Except reverse No

SCIA0645E

NEUTRAL POSITION SWITCH
q Check continuity.
Gear position Continuity
Neutral Yes
Except neutral No

SCIA0645E

Revision: 2004 December MT-12 2004.5 350Z
SHIFT CONTROL

SHIFT CONTROL PFP:34103
A
Removal and Installation ACS004NP

PCIB0689E

1. Insulator 2. Seat 3. Control lever J
4. Control lever spring 5. Guide plate 6. Control lever boot
7. Hole cover 8. Shift knob
K
REMOVAL
1. Remove the shift knob with the following procedure.
a. Disconnect console boot from center console. Refer to IP-11, L
"Removal and Installation" .

PCIB0596E

Revision: 2004 December MT-13 2004.5 350Z
SHIFT CONTROL

b. Lift console boot, and push down hole cover. Set water pump
plier and others to control lever assembly.
CAUTION:
Put waste cloth between water pump plier and control lever
assembly to avoid damaging control lever assembly.

PCIB0222E

c. Set monkey wrench to shift knob.
CAUTION:
Put waste cloth between shift knob and suitable plier to
avoid damaging shift knob.

PCIB0246E

d. Turn monkey wrench with water pump plier and others fixed.
Loosen shift knob, and remove shift knob from control lever
assembly.
NOTE:
Remove shift knob from control assembly with water pump plier
and others fixed. Because a certain power to turn shift knob is
necessary even after adhesive is peeled.
2. Loosen the shift knob to remove the control lever.
3. Remove console boot. Refer to IP-11, "Removal and Installa-
tion" .
PCIB0247E

4. Push back the boot, remove control lever assembly mounting
bolt, and separate control lever and control rod assembly.

SCIA1671E

5. Remove the mounting bolts to remove the hole cover.
6. Remove the control lever boot.

SCIA1511E

Revision: 2004 December MT-14 2004.5 350Z
SHIFT CONTROL

7. Remove guide plate mounting bolts, and then remove control A
lever assembly and control lever spring.

SCIA1365E
D
INSTALLATION
1. Set control lever assembly and control lever spring in the control lever housing assembly and loosely
mount the guide plate. E
2. After installing control lever assembly in the control rod assem-
bly, tighten bolts to the specified torque. Refer to MT-13,
"Removal and Installation" . F

H
SCIA1671E

3. Shifting control lever assembly to 6th gear, the control lever I
assembly is light pressed to the reverse side.
4. At the point where the control lever assembly stops, bring the
guide plate closer until guide plate stopper contacts control lever J
assembly claw, and then loosely tighten mounting bolt A.

SCIA1665E

Revision: 2004 December MT-15 2004.5 350Z
SHIFT CONTROL

5. Shifting control lever assembly to 5th gear, the control lever
assembly light pressed to the reverse side.
6. At the point where control lever assembly stops, bring guide
plate closer until the guide plate stopper contacts control lever
assembly claw, and then loosely tighten mounting bolt C. Refer
to MT-13, "Removal and Installation" .
7. Tighten guide plate bolts A and B to the specified torque. Refer
to MT-13, "Removal and Installation" .
8. Install control lever boot.
9. Install hole cover and tighten bolt to the specified torque. Refer
to MT-13, "Removal and Installation" .
10. Install console boot. Refer to IP-11, "Removal and Installation" .

SCIA1666E

11. As shown in the figure, assemble seat and insulator to control
lever assembly.
CAUTION:
Do not reuse the insulator.
12. Apply locking sealant to control lever threads, install shift knob.
CAUTION:
Remove the remaining adhesive on control lever and shift
knob threads.

SCIA1771E

13. Put the shift knob in the correct position as the following indicates.

Revision: 2004 December MT-16 2004.5 350Z
SHIFT CONTROL

a. When tightening shift knob, if shift knob position is the correct
position a less than 1/2 rotation from starting resistance, tighten A
1 more rotation and set the correct position again.
b. If shift knob position is the correct position more than 1/2 rotation
from starting resistance, tighten and set the correct position. B
CAUTION:
q Do not adjust the knob with loosing.
q After adjusting to regular position, until 30 minute passes MT
since a locking sealant because stiff. Do not operate the
shift intensely such as screwing or turning the shift knob to
opposite direction.
D

G
SCIA1774E

INSPECTION AFTER INSTALLATION
After installing, confirm the following items: H
q When control lever assembly is shifted to each position, make sure there is no binding or disconnection in
each boot.
q When shifted to each position, make sure there is no noise, bending, and backlash. Especially when con- I
trol lever assembly is shifted to 5th, 6th without pressing downward, check for bending.
q When control lever assembly is shifted to 1st, 2nd side and 5th, 6th side, confirm control lever assembly
returns to neutral position smoothly. J
q In any position other than reverse, confirm that control lever assembly can be pressed downward.
q With control lever assembly pressed downward, confirm that it can be shifted to reverse.
q When shifted from reverse to neutral position, confirm control lever assembly returns to neutral position K
smoothly with spring power.
q Without control lever assembly pressed downward, confirm that it cannot be shifted to reverse.
L

Revision: 2004 December MT-17 2004.5 350Z
AIR BREATHER HOSE

AIR BREATHER HOSE PFP:31098

Removal and Installation ACS004NQ

Refer to the figure for air breather hose removal and installation information.

PCIB0690E

1. Air breather hose

CAUTION:
q Make sure there are no pinched or blocked areas on the air breather hose caused by bending or
winding when installing it.
q Insert overlap width of air breather hose as far as it will go.

Revision: 2004 December MT-18 2004.5 350Z
TRANSMISSION ASSEMBLY

TRANSMISSION ASSEMBLY PFP:32010
A
Removal and Installation from Vehicle ACS004NR

G
PCIB0691E

1. Transmission case 2. Rear engine mounting member 3. Insulator

REMOVAL H
1. Disconnect battery negative cable.
2. Remove front cross bar with power tool. Refer to FSU-9, "REMOVAL" .
3. Remove catalytic converter stay mounting nuts and bolts, and I
then remove catalytic converter bracket. Refer to EX-3,
"Removal and Installation" .
J

L
SCIA1471E

4. Remove nut connecting catalytic converter to exhaust manifold, and then remove catalytic converter and
exhaust front tube as one unit. M
5. Remove propeller shaft. Refer to PR-7, "Removal and Installation" .
CAUTION:
Do not impact or damage propeller shaft tube.
6. Remove control rod mounting bolts and then separate shift lever
assembly from the control rod assembly.

SCIA1364E

Revision: 2004 December MT-19 2004.5 350Z
TRANSMISSION ASSEMBLY

7. Using a screwdriver wrapped in tape to remove claw and then
separate console boot from the center console. Refer to IP-11,
"Removal and Installation" .

SCIA1473E

8. Remove hole cover mounting bolts and then separate hole
cover from the floor panel.
9. Separate control lever boot from the guide plate.

SCIA1590E

10. Remove guide plate mounting bolts and then separate shift lever
assembly from the shift lever housing assembly.

SCIA1591E

11. Remove clutch operating cylinder mounting bolts and then separate heat insulator and clutch operating
cylinder from the transmission case. Refer to CL-11, "Removal and Installation" .
12. Remove crankshaft position sensor (POS).
CAUTION:
q Do not subject it to impact by dropping or hitting.

q Do not disassemble.

q Do not allow metal filings, etc., to get on the sensor's
front edge magnetic area.
q Do not place in an area affected by magnetism.

13. Disconnect neutral position switch and back-up lamp switch.
14. Separate heated oxygen sensor 2 wire harness, crankshaft
position sensor (POS), wire harness, back-up lamp switch wire SCIA1476E

harness and PNP switch wire harness from the transmission.

15. Remove starter motor. Refer to SC-19, "Removal and Installation" .
16. Remove rear cover plate. Refer to EM-27, "Removal and Installation" .
17. Set transmission jack to the transmission.
CAUTION:
When setting transmission jack, be careful not to contact with the switch.

Revision: 2004 December MT-20 2004.5 350Z
TRANSMISSION ASSEMBLY

18. Remove rear engine mounting member. Refer to EM-103,
"Removal and Installation" . A
19. Remove engine and transmission mounting bolts with power
tool.
20. Remove transmission from the vehicle. B

SCIA1531E

D
INSTALLATION
Install in the revers order of removal procedure, following the cautions below:
q When installing transmission to the engine, install mounting bolts in accordance with the standards below. E
LHD Model
Bolt No. 1 2 3 4 5
F
Quantity 1 5 2 2 2
55 65 50 35 65
" " mm (in)
(2.17) (2.56) (1.97) (1.38) (2.56)
G
Tightening torque 75 55.4 46.6 55.4
N

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